Prefabricated wall component apparatus and system

ABSTRACT

A pre-fabricated metal stud wall apparatus and system. End studs are placed non-parallel at a 45-degree angle. Abutting adjacent 45-degree walls together, with no loss in square footage can easily create corners. The walls can be made independent of building plan. As such, any 2-foot 8-foot section (or whatever length) can simply be purchased and conformed to any building plan regardless of style or shape (octagonal, hexagonal, square and the like). Each stud includes a series of slots. When the two angled studs are placed side by side, the slots align. A hole present at the end of the wall allows a rod to be placed into it. The rod includes a series of fingers that insert into the aligned slots, thereby locking the adjacent walls together. The walls can include any other number of cutouts for windows, utilities and the like.

BACKGROUND

I. Field of the Invention

The present invention relates generally to the field construction andmore particularly to prefabricated wall component apparatus and system.

II. Description of the Related Art

Prefabricated steel stud walls are conventionally used to constructvarious structures and dwellings, such as modular homes, and aretypically fabricated with parallel metal studs in pre-selected lengths,such as 2-foot, 4-foot, 6-foot, 8-foot and the like. The resultingcomponent is a planar generally rectangular wall component with squaredends and edges. When the prefabricated walls are placed together to makea structure such as a home, square footage can be easily lost becausethe walls must be overlapped to create a corner, generally resulting inthe loss of one side of the corner by the thickness of the overlappingpanel. In addition, lengths of the prefabricated walls often have to becustom made depending on the building plan.

SUMMARY

In general, the invention features a pre-fabricated metal stud wall as aprefabricated wall component apparatus. In the present invention, theend studs are placed non-parallel at a 45-degree angle. In this way,abutting adjacent 45-degree walls together, with no loss in squarefootage can easily create corners. More importantly, the walls can bemade independent of building plan. As such, any 2- foot 8-foot section(or whatever length) can simply be purchased and conformed to anybuilding plan regardless of style or shape (octagonal, hexagonal, squareetc.) Furthermore, each stud includes a series of slots. When the twoangled studs are placed side by side (for example, when a corner isformed by placing two adjacent walls), the slots align. A hole presentat the end of the wall allows a rod to be placed into it. The rodincludes a series of fingers that insert into the aligned slots, therebylocking the adjacent walls together. The walls can include any othernumber of cutouts for windows, utilities and the like.

In general, in one aspect, the invention features a prefabricated wallapparatus, including an outer wall, an inner wall, vertical studspositioned between the inner and outer walls and connected perpendicularto an top plate and a sill plate and end studs positioned on either endsof the vertical studs and rotated at a 45 degree angle with respectiveto the inner and outer walls.

In one implementation, the apparatus further includes a thermal breaklocated between the studs and the outer wall.

In another implementation, the thermal break forms an airspace betweenthe studs and the outer wall. The airspace can include a two partexpanding foam thermal break, which also provides rigidity in theairspace.

In another implementation, the apparatus further includes a series ofslots positioned along the end studs.

In another implementation, the apparatus further includes an upperopening located on the top plate adjacent the end studs.

In still another implementation, the connection between the top plateand the end studs has an isosceles trapezoid profile.

In yet another implementation, the base angles of the isoscelestrapezoid profile are 45°.

In another aspect, the invention features a prefabricated wall system,including a first prefabricated wall panels having an top plate and twoend studs, the top plate and end studs forming base angles less than 90degrees, a second prefabricated wall panel having at least one end studabutted against and flush with one of the end studs of the firstprefabricated wall panel, thereby forming an outer corner and a thirdprefabricated wall panel having at least one end stud abutted againstone of the end studs of the first prefabricated wall panel such that aright angle space is formed between the end studs of the first and thirdprefabricated panels.

In one implementation, the system further includes a series of slotsalong each of the end studs.

In another implementation, the series of slots on the end stud of thefirst prefabricated panel that is abutted against and flush with the endstud of the second prefabricated wall panel are aligned with the seriesof slots on the second prefabricated wall panel.

In another implementation, the system further includes an top plate oneach of the second and third prefabricated wall panels.

In another implementation, the system further includes an opening oneach of the top plates adjacent the series of slots on the end studs.

In another implementation, the system further includes a rod locatedwithin at least one of the openings of the first and secondprefabricated panels and positioned parallel the end studs.

In still another implementation, the system further includes a series offingers positioned along the rod.

In yet another implementation, the fingers are positioned within thealigned slots of the end studs of the first and second prefabricatedwall panels.

In another aspect, the invention features a prefabricated wall kit,including a prefabricated wall panel having vertical studs positionedbetween and perpendicular to an top plate and a sill plate and end studspositioned on either ends of the vertical studs and having base anglesof 45 degrees, the end studs having a series of slots along the studs,and an elongated rod having a series of fingers, for insertion in anopening on the top plate so that the fingers fit within the series ofslots so that the prefabricated panel can be connected and locked toanother prefabricated panel having a corresponding end stud with aseries of slots.

One advantage of the invention is that little to no square footage islost when the panel apparatuses are connected to one another to createwalls and corners.

Another advantage of the invention is that the prefabricated panels canbe preformed into a variety of dimensions.

Another advantage of the invention is that it enables nominalstock/standard inventory on-hand.

Another advantage of the invention is that it is adaptable to virtuallyall house plans.

Another advantage of the invention is that corners can be secured bylocking adjacent panels forming the corners to one another.

Another advantage of the invention is that panels can be subsequentlydetached to expand architectural designs.

Other objects, advantages and capabilities of the invention are apparentfrom the following description taken in conjunction with theaccompanying drawings showing the preferred embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a top view of an embodiment of a prefabricated wallsystem;

FIG. 1B illustrates a side view of an embodiment of a prefabricated wallpanel apparatus;

FIG. 2 illustrates a partial top view of an embodiment of aprefabricated wall panel apparatus;

FIG. 3 illustrates a side view of an embodiment of a prefabricated wallpanel apparatus;

FIG. 4A illustrates a partial side view of constituent components of aprefabricated wall system;

FIG. 4B illustrates a top view of an embodiment of a connection rod;

FIG. 5 illustrates a partial close up view of an embodiment of aprefabricated wall system;

FIG. 6 illustrates an upper partial view of an embodiment of aprefabricated wall system;

FIG. 7 illustrates a lower partial view of an embodiment of aprefabricated wall system;

FIG. 8 illustrates a top view of another embodiment of a prefabricatedwall system;

FIG. 9 illustrates a partial top view of another embodiment of aprefabricated wall system; and

FIG. 10 illustrates two embodiments of connecting plates.

DETAILED DESCRIPTION

Referring to the drawings wherein like reference numerals designatecorresponding parts throughout the several figures, reference is madefirst to FIG. 1A that illustrates a top view of an embodiment of aprefabricated wall system 100. In general, the system 100 includes anumber of prefabricated wall panels 105 (prefabricated wall panelapparatuses 105). In a typical embodiment, the panels 105 are steel studpanels, although it is understood that other materials such as wood canbe used in other embodiments. Typically, the panels 105 include an innerwall 110 and an outer wall 115. The inner and outer walls 110, 115 canbe a variety of known materials such as wood, particle board, ply wood,chip/wafer board and the like. In a typical embodiment, additionalinterior covering is added such as dry wall, and additional exteriorcovering is added such as vinyl siding or other suitable materials.

Referring still to FIG. 1A and also to FIG. 1B that illustrates a sideview of an embodiment of a prefabricated wall panel apparatus 105, it isappreciated that the panels 105 can generally include an upper and sillplate 120, 125 as well several studs 130. The panel 105 can furtherinclude end studs 140. It is appreciated that the studs 130, 140typically include slots 141. In general, those skilled in the artappreciate that the cutouts are used to decrease weight and increasestrength of steel studs. In addition, the cutouts also allow formechanical chase to be installed as needed for electrical, multi-mediaand phone lines, as well as for HVAC, Freon and other utilities.

In a typical implementation, the upper and sill plates 120, 125 arearranged parallel to one another. The studs 130 are arranged parallel toone another and in a vertical generally perpendicular position withrespect to the upper and lower studs 120, 125. The end studs 140 arealso arranged generally orthogonal with respect to the upper and sillplates 120, 125. However, the end studs 140 are arranged in a positionthat is rotated at an angle such that the ends of the panels 105 form anon-square end. In a typical embodiment, the top profile of each panel105 is an isosceles trapezoid, the two end studs 140 representing equalnon-parallel sides of the trapezoid. Furthermore, the base angles, A, ofthe top profile are 45 degrees in a typical implementation. It isunderstood that in other embodiments and implementations, the base anglecan be other angles other than 45 degrees. However, it is appreciatedthat the 45-degree base angle has several advantages that are nowdiscussed in further detail.

In general, it is desirable for panels such as panels 105 to havepre-fabricated and predictable dimensions, thereby allowing a modularhome, for example, to be predictably constructed. As such, the panels105 can be prefabricated into a variety of dimensions (lengths) such asbut not limited to 2-foot, 4-foot and 8-foot sections. It is understoodthat several standard length sections can be made available depending onthe needs of the user. When choosing a predictable section, it isdesired to maintain the integrity of dimension, particularly whencreating corners in the structure. To preserve length integrity whenmaking corners, two adjoining panels 105 can be butted together as shownin FIG. 1 in the four corners of the system 100. By having the endsstuds be positioned at 45-degree angles, two end studs of adjacentpanels 105 in the corners can be butted together to form a 90-degreecorner as desired. The outer walls 115 having the predeterminedpredictable length can create the corner created without affecting thepredictable length. For example, if a corner is to be formed with two 8foot panels 105, the resulting corner includes two 8-foot panels 105, incontrast to the prior art in which a corner would be formed byoverlapping two ends of panels at a corner resulting in the loss oflength on one side of the corner by the thickness of the overlappingpanel. The 45-degree abutting of adjacent panels 105 when creating acorner has further advantages as discussed further in the descriptionbelow.

It is appreciated that since the panels 105 desirably prefabricated, thesame panels 105 are used to create straight walls of a structure and notjust corners of the structure. The same panels 105 can advantageouslyabutted together side by side to create a straight wall section, asfurther illustrated in FIG. 1. The resulting abutment of the panels 105side by side to create a straight wall section results in a right angleat the end studs 140 joined side by side. The inner walls 110 of theadjacent panels easily cover the right angle during construction. It isappreciated that the right angle created between the straight wallsallows an access space that can advantageously be used to accessdesirable floor space. For example, if the walls are built on a basementor crawlspace on a wood floor, holes can be cut into the floor for usewith utilities such as electrical lines, plumbing gas lines etc andchase for other mechanical installation. Such access is easy and iseasily concealed once the inner walls are installed.

FIG. 3 illustrates a side view of an embodiment of a prefabricated wallapparatus panel 105 illustrating the many features described above andbelow.

FIG. 2 illustrates a partial top view of an embodiment of aprefabricated wall apparatus panel 105. As described above, the panel105 includes an top plate 120 shown in partial breakaway view toillustrate the top plate 120 connection to the studs 130 in the panel105. One of the end studs 140 is shown connected to the top plate 120.The end stud 140 is connected to the panel at an angle as discussedabove such that the end stud 140 is rotated at angles of A and A′ withrespect to the inner and outer walls 110, 115 as shown. It isappreciated that in a typical implementation A=45° and A′=135°. It isfurther understood that other angles are possible in other embodimentsto create other corner orientations. However, it is appreciated that the45° angle orientation of the end studs are desirable for to createcorners for structures as discussed above. In a typical implementation,the angles A, A′ are supplementary angles.

Still referring to FIG. 2, the panel 105 further includes the inner andouter walls 110, 115 as discussed above. It is generally appreciatedthat the walls 110, 115 are used to provide walls for the prefabricatedpanels 105 onto which other suitable wall material can be mounted.Therefore, it is appreciated that, for example, dry wall can be furtherconnected to the inner wall upon completion of the structure. Inaddition, for example, suitable external walls can be connected to theouter wall 115, such as vinyl or brick. In addition, the panel 105generally includes spacing, d, between the studs 130 and the inner andouter walls 110, 115 to provide general thermal insulation as well as aspace to add additional insulation. In general, a thermal break 145 canbe positioned between the studs 130 and the outer wall 115.

Referring again to FIG. 1A, the system 100 further includes openings 150cut into the top plates thereby creating access to the butted end studs140 at the corners. In addition, as mentioned above, a right angle isformed between the end studs 140 for those panels 105 on the straightwalls. Both the openings 150 and the right angles provide access to theslots 141 on the end studs. This access provides one of the additionaladvantages of the end studs 140 being butted together or placed side byside, which is now discussed.

FIG. 4A illustrates a partial side view of constituent components of aprefabricated wall system 100. As described above, the panels 105 cangenerally include an upper and sill plate 120, 125 as well several studs130. The panel 105 can further include end studs 140. It is appreciatedthat the studs 130, 140 typically include slots 141. In a typicalimplementation, when two of the corner panels 105 are abutted to oneanother the slots 141 on each of the end studs align with one another.This alignment creates a conduit through which the end studs 140 of therespective panels 105 can be coupled to one another thereby connectingthe respective end studs 140 and therefore the two panels comprising thecorner to one another. In this way, the panels 105 can be secured to oneanother. A connection rod 200 can be inserted into either of the panelopenings 150 to accomplish this coupling.

In general, the connection rod 200 is elongated and runs the entireheight of the structure or individual panel 105. In one embodiment, therod 200 can include two elongated rectangular panels 205, 210 connectedto each other at a right angle (or orthogonal). FIG. 4B illustrates atop view of an embodiment of a connection rod 200 illustrating theorthogonal arrangement of the rod 200. The rod 200 can further include aseries of fingers 215 that are generally pointed in a downwarddirection. As such, when the rod 200 is inserted into the openings 150,the fingers 215 engage with the aligned slots 141 thereby locking theabutted end studs 140 to one another.

FIG. 5 illustrates a partial close-up top view of an embodiment of aprefabricated wall system 100. AS discussed above, two panels 105 can beabutted to one another to form a corner. Each panel includes the topplate 120 having an opening 150 into which the rod 200 has been placedallowing the fingers 215 to insert into the aligned slots 141. Each ofthe end studs 140 can further include one or more sleeves 170 into whichthe rod 200 is placed so that the rod 200 can be guided along the innerportions of the end studs 140. In this way, as the rod 200 is insertedinto the openings, the sleeves 170 help prevent the rod 200 from movingin directions other than the desired direction along the end studs,thereby allowing the fingers 215 to be efficiently inserted into thealigned slots 141.

FIG. 6 illustrates an upper partial view of an embodiment of aprefabricated wall system 100. This view illustrates the sameorientation of the rod 200 as it is placed into the openings 150 to lockthe end studs 140 to one another. Each panel includes the top plate 120having an opening 150 into which the rod 200 has been placed allowingthe fingers 215 to insert into the aligned slots 141. Each of the endstuds 140 can further include one or more sleeves 170 into which the rod200 is placed so that the rod 200 can be guided along the inner portionsof the end studs 140. It is further appreciated that FIGS. 5 and 6illustrate that the rod 200 can be placed into either of the openings150 to accomplish the coupling or locking together of the end studs 140and thereby the respective panels 105. As such, the sleeve on the leftside of FIG. 6 is illustrated as without a rod.

FIG. 7 illustrates a lower partial view of an embodiment of aprefabricated wall system 100. This view illustrates that each panelincludes the sill plate 125 connected to the end studs 140 as describedabove. Each of the end studs 140 can further include one or moreadditional sleeves 170. As described above, the sleeves 170 help preventthe rod 200 from moving in directions other than the desired directionalong the end studs, thereby allowing the fingers 215 to be efficientlyinserted into the aligned slots 141. In addition, the end studs 140 canfurther include a terminal sleeve 175 that tapers from top to bottom sothat the rod 200 can fit into the top of the terminal sleeve 175 but notexit from the bottom of the terminal sleeve 175. The tapered profile ofthe terminal sleeve 175 therefore allows the rod 200 to move even closerto the end studs and forced the fingers 215 further into the alignedslots 141. In this way, the weight of the rod 200 forces the rod 200into an even more secured position against the end studs 140.

In general, the end studs 140 that are abutted to one another in thestraight wall portions are generally secured in the structure by beingconnected to the respective foundations. The rods 200 allow the cornerapplications of the structures to be secured. In this way, the corners,where structural vulnerability tends to be located are furtherreinforced by the insertion of the rods 200. Furthermore, it isappreciated that top caps 180 can be placed over the openings 150 tocover the rods 200. If it is desired to subsequently expand thestructure, the top caps 180 can be removed and the rods 200 can bepulled out of the openings. Panels 105 can subsequently be removed andadditional panels 105 added in order to expand on the structure.

It is appreciated that many architectural designs are possible with theembodiments of the prefabricated wall system 100 and panel apparatuses105 described herein. For example, the corners of the structure may beformed such that the end studs 140 are not abutted to one another butshare a common plane of orientation, P, such as illustrated in FIG. 8 at405. It is further appreciated that a corner 410 can be constructed asneeded for those end studs 140 that share the common plane oforientation.

It is further appreciated that other architectural designs are possiblewith the embodiments of the standardized prefabricated systems andapparatuses described herein. For example, FIG. 9 illustrates a partialtop view of another embodiment of a prefabricated wall system 500. Theexample illustrates that several panels 105 can be used for anarchitectural profile of a partial hexagon, which can be used for baywindows and the like. In general, the internal angles of a hexagon are120°. Therefore, the space 505 that remains between the end studs 140 is30° after subtracting out the 45° of the two end studs. It is understoodthat the angles described are illustrative only and can differ in actualpractice. In addition it is understood that various other designs canfurther be contemplated using the embodiments of the systems andapparatuses described herein, such as but not limited to octagonal anddecagonal profiles and the like.

FIG. 10 illustrates two embodiments of connecting plates 600, 650. Theconnecting plate 600 is typically used to cover the corners formed whenrespective end studs have been connected as described above. Theconnecting plate 650 is used to cover the straight connections when twoof the end studs are placed side by side to create long walls asdescribed above. It is appreciated that other angles can be formed intothe connecting plates 600, 650, such as to accommodate the top cornerformed, say, between two adjacent walls of the hexagonal exampleillustrated in FIG. 9. It is further appreciated that the connectingplates 600, 650 provide additional stability and alignment of theadjacent walls.

Steel studs have been described in the embodiments herein. However, itis understood that other materials can be advantageously implementedsuch as but not limited to wood, fiberglass and extruded fiberglass.

Therefore, the foregoing is considered as illustrative only of theprinciples of the invention. Further, various modifications may be madeof the invention without departing from the scope thereof and it isdesired, therefore, that only such limitations shall be placed thereonas are imposed by the prior art and which are set forth in the appendedclaims.

1. A prefabricated wall apparatus, comprising: an outer wall; an innerwall; vertical studs positioned between the inner and outer walls andconnected perpendicular to an top plate and a sill plate; and end studspositioned on either ends of the vertical studs and rotated at a 45degree angle with respective to the inner and outer walls.
 2. Theapparatus as claimed in claim 1 further comprising a thermal breaklocated between the studs and the outer wall.
 3. The apparatus asclaimed in claim 2 wherein the thermal break forms an airspace betweenthe studs and the outer wall.
 4. The apparatus as claimed in claim 1further comprising a series of slots positioned along the end studs. 5.The apparatus as claimed in claim 4 further comprising an upper openinglocated on the top plate adjacent the end studs.
 6. The apparatus asclaimed in claim 1 wherein the connection between the top plate and theend studs have an isosceles trapezoid profile.
 7. The apparatus asclaimed in claim 6 wherein the base angles of the isosceles trapezoidprofile are 45°.
 8. A prefabricated wall system, comprising: a firstprefabricated wall panels having an top plate and two end studs, the topplate and end studs forming base angles less than 90 degrees; a secondprefabricated wall panel having at least one end stud abutted againstand flush with one of the end studs of the first prefabricated wallpanel, thereby forming an outer corner; and a third prefabricated wallpanel having at least one end stud abutted against one of the end studsof the first prefabricated wall panel such that a right angle space isformed between the end studs of the first and third prefabricatedpanels.
 9. The system as claimed in claim 8 further comprising a seriesof slots along each of the end studs.
 10. The system as claimed in claim9 wherein the series of slots on the end stud of the first prefabricatedpanel that is abutted against and flush with the end stud of the secondprefabricated wall panel are aligned with the series of slots on thesecond prefabricated wall panel.
 11. The system as claimed in claim 10further comprising an top plate on each of the second and thirdprefabricated wall panels.
 12. The system as claimed in claim 11 furthercomprising an opening on each of the top plates adjacent the series ofslots on the end studs.
 13. The system as claimed in claim 12 furthercomprising a rod located within at least one of the openings of thefirst and second prefabricated panels and positioned parallel the endstuds.
 14. The system as claimed in claim 13 further comprising a seriesof fingers positioned along the rod.
 15. The system as claimed in claim14 wherein the fingers are positioned within the aligned slots of theend studs of the first and second prefabricated wall panels.
 16. Aprefabricated wall kit, comprising: a prefabricated wall panelcomprising: vertical studs positioned between and perpendicular to antop plate and a sill plate; end studs positioned on either ends of thevertical studs and having base angles of 45 degrees, the end studshaving a series of slots along the studs; and an elongated rod having aseries of fingers, for insertion in an opening on the top plate so thatthe fingers fit within the series of slots so that the prefabricatedpanel can be connected and locked to another prefabricated panel havinga corresponding end stud with a series of slots.